2005 MERCEDES-BENZ SPRINTER Service Repair Manual

(1) Disconnect and isolate the battery negative
cable.
(2) Move the driver side front seat to its most for-
ward position for easiest access to the seat riser
cover panel (Fig. 15).
(3) Remove the cover panel from the top of the
driver side seat riser.
(4) Remove the fog lamp relay by grasping it
firmly and pulling it straight out of the relay connec-
tor.
INSTALLATION
Fog lamps are optional equipment on this model.
On vehicles equipped with fog lamps, a fog lamp
relay is located in a dedicated connector of the vehi-
cle wire harness. This connector is snapped into an
opening in a stamped sheet metal bracket which is
secured with screws within the driver side front seat
riser just beneath the seat riser cover panel.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, SEAT BELT TENSIONER, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE (GROUND) CABLE, THEN WAIT
TWO MINUTES FOR THE SYSTEM CAPACITOR TO
DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE SUPPLEMENTALRESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
(1) Position the fog lamp relay to the relay connec-
tor.
(2) Align the fog lamp relay terminals with the
terminal cavities in the relay connector.
(3) Using hand pressure, push firmly and evenly
on the top of the fog lamp relay until the terminals
are fully seated in the relay connector.
(4) Position the cover panel onto the top of the
driver side seat riser (Fig. 15).
(5) Install and tighten the two screws that secure
the cover panel to the top of the seat riser under the
driver side front seat.
(6) Move the driver side front seat back to its driv-
ing position.
(7) Reconnect the battery negative cable.
FOG LAMP SWITCH
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the cluster bezel from the instrument
panel (Fig. 16). (Refer to 23 - BODY/INSTRUMENT
PANEL/CLUSTER BEZEL - REMOVAL).
Fig. 15 Seat Riser Cover
1 - DRIVER SEAT BACK
2 - COVER PANEL
3 - SCREW (2)
4 - SEAT RISER
Fig. 16 Fog Lamp Switch
1 - FOG LAMP SWITCH
2 - SCREW (2)
3 - CLUSTER BEZEL
4 - TO REAR WINDOW DEFOGGER SWITCH (OPTION AL)
5 - TO HEADLAMP LEVELING SWITCH
6 - TO FOG LAMP SWITCH (OPTIONAL)
VALAMPS/LIGHTING - EXTERIOR 8L - 11
FOG LAMP RELAY (Continued)

(3) From the back of the cluster bezel, squeeze the
two latches on the fog lamp switch body and push
the switch out through the face of the bezel (Fig. 17).
(4) Remove the fog lamp switch from the face of
the cluster bezel.
INSTALLATION
(1) Position the fog lamp switch to the proper
mounting hole on the face of the cluster bezel (Fig.
16).
(2) Using hand pressure, push the fog lamp switch
firmly and evenly into the switch mounting hole of
the cluster bezel until both of the latches on the
switch body are fully engaged.
(3) Reinstall the cluster bezel onto the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
CLUSTER BEZEL - INSTALLATION).
(4) Reconnect the battery negative cable.
FRONT LAMP UNIT
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the front grille from the vehicle. (Refer
to 23 - BODY/EXTERIOR/GRILLE - REMOVAL).
(3) Remove the two screws that secure the cover at
the inboard side of the front lamp unit (Fig. 18).
(4) Remove the cover from the front lamp unit.
(5) From the engine compartment, disconnect the
vehicle wire harness connector from the connector
receptacle for the front lamp unit.
(6) Remove the four screws that secure the front
lamp unit to the front of the vehicle.(7) Remove the front lamp unit from the front of
the vehicle.
INSTALLATION
(1) Position the front lamp unit to the front of the
vehicle (Fig. 18).
(2) Install and tighten the four screws that secure
the front lamp unit to the front of the vehicle.
(3) From the engine compartment, reconnect the
vehicle wire harness connector to the connector
receptacle for the front lamp unit.
(4) Position the cover to the front lamp unit.
(5) Install and tighten the two screws that secure
the cover at the inboard side of the front lamp unit.
(6) Reinstall the front grille onto the vehicle.
(Refer to 23 - BODY/EXTERIOR/GRILLE - INSTAL-
LATION).
(7) Reconnect the battery negative cable.
(8) Check and adjust the front lamp alignment as
required. (Refer to 8 - ELECTRICAL/LAMPS/LIGHT-
ING - EXTERIOR/FRONT LAMP UNIT - ADJUST-
MENTS).
ADJUSTMENTS
ADJUSTMENT - FRONT LAMP UNIT
VEHICLE PREPARATION FOR FRONT LAMP UNIT
ALIGNMENT
(1) Verify headlamp dimmer (multi-function)
switch, fog lamp switch (if equipped), and high beam
indicator operation.
(2) Verify that the headlamp leveling switch is in
the ª0º position.
Fig. 17 Fog Lamp Switch Remove/Install
1 - FOG LAMP SWITCH
2 - LATCH (2)
3 - CLUSTER BEZEL
Fig. 18 Front Lamp Unit Remove/Install
1 - SCREW (2)
2 - COVER
3 - SCREW (4)
4 - LAMP UNIT
5 - WIRE HARNESS CONNECTOR
8L - 12 LAMPS/LIGHTING - EXTERIORVA
FOG LAMP SWITCH (Continued)

(3) Repair or replace any faulty or damaged com-
ponents that could interfere with proper lamp align-
ment.
(4) Verify proper tire inflation.
(5) Clean front lamp unit lenses.
(6) Verify that the cargo compartment is not
heavily loaded. Vehicle should be at or near curb
weight.
(7) The fuel tank should be ªFull.º Add 2.94 kilo-
grams (6.5 pounds) of weight over the fuel tank for
each estimated gallon of missing fuel.
(8) Load the driver's seat with 75 kilograms (165
pounds) of weight.
FRONT LAMP UNIT ALIGNMENT
(1) Position the vehicle on a level surface.
(2) Turn On the headlamp low beams or the fog
lamps (if equipped).
(3) Open the hood.
(4) Set up the headlamp adjuster according to the
instructions provided by the manufacturer of the
unit.
(5) Adjust the front lamp unit reflector as required
by turning the adjustment screws in or out (Fig. 19).(6) When properly aligned, the low beam head-
lamps and, if equipped, fog lamps should provide a
cut-off pattern as shown in (Fig. 20) and (Fig. 21).
Repeat the adjustment procedure as necessary to
obtain the recommended cut-off patterns.
Fig. 19 Front Lamp Unit Adjusting Screws
1 - HORIZONTAL ADJUSTMENT
2 - VERTICAL ADJUSTMENT
Fig. 20 Low Beam Headlamp Cut-Off Pattern
Fig. 21 Fog Lamp Cut-Off Pattern
VALAMPS/LIGHTING - EXTERIOR 8L - 13
FRONT LAMP UNIT (Continued)

FRONT POSITION LAMP BULB
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Disengage and swing the retainers that secure
the front lamp unit rear cover to each side of the
lamp housing and remove the cover (Fig. 22).
(3) Pull the position lamp bulb holder straight out
to remove it from the front lamp unit reflector (Fig.
23).(4) Remove the position lamp bulb from the bulb
holder.INSTALLATION
(1) Install the position lamp bulb into the bulb
holder (Fig. 23).
(2) Push the position lamp bulb holder straight
into the mounting hole in the front lamp unit reflec-
tor.
(3) Position the front lamp unit rear cover onto the
lamp housing and engage the retainers over each
side of the cover to secure it (Fig. 22).
(4) Reconnect the battery negative cable.
FRONT TURN/PARK/SIDE
MARKER LAMP BULB
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Locate the turn/park/side marker bulb holder
on the rear outboard side of the front lamp unit
housing (Fig. 24).
Fig. 22 Front Lamp Unit Bulbs Remove/Install
1 - COVER RETAINER (2)
2 - BULB RETAINER (3)
3 - FOG LAMP BULB (OPTIONAL)
4 - COVER
5 - LOW BEAM BULB
6 - POSITION BULB
7 - HIGH BEAM BULB
8 - TURN/PARK/SIDE MARKER BULB
9 - FRONT LAMP UNIT
Fig. 23 Position Lamp Bulb Remove/Install
1 - BULB HOLDER
2 - LAMP REFLECTOR
Fig. 24 Front Lamp Unit Bulbs Remove/Install
1 - COVER RETAINER (2)
2 - BULB RETAINER (3)
3 - FOG LAMP BULB (OPTIONAL)
4 - COVER
5 - LOW BEAM BULB
6 - POSITION BULB
7 - HIGH BEAM BULB
8 - TURN/PARK/SIDE MARKER BULB
9 - FRONT LAMP UNIT
8L - 14 LAMPS/LIGHTING - EXTERIORVA

(3) Rotate the bulb holder counterclockwise about
30 degrees and pull it straight out from the lamp
housing (Fig. 25).
(4) Remove the bulb from the front turn/park/side
marker bulb holder.
INSTALLATION
(1) Install the bulb into the front turn/park/side
marker bulb holder.
(2) Insert the bulb holder straight into the front
lamp unit housing and rotate the bulb holder clock-
wise about 30 degrees to lock it into place (Fig. 25).
(3) Reconnect the battery negative cable.
HEADLAMP LEVELING MOTOR
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Disengage and swing the retainers that secure
the front lamp unit rear cover to each side of the
lamp housing and remove the cover (Fig. 26).
(3) Disconnect the front lamp unit wire harness
connector from the connector receptacle for the head-
lamp leveling motor (Fig. 27).
Fig. 25 Front Turn/Park/Side Marker Bulb Remove/
Install
1 - LAMP HOUSING
2 - BULB HOLDER
Fig. 26 Front Lamp Unit Bulbs Remove/Install
1 - COVER RETAINER (2)
2 - BULB RETAINER (3)
3 - FOG LAMP BULB (OPTIONAL)
4 - COVER
5 - LOW BEAM BULB
6 - POSITION BULB
7 - HIGH BEAM BULB
8 - TURN/PARK/SIDE MARKER BULB
9 - FRONT LAMP UNIT
Fig. 27 Headlamp Leveling Motor
1 - HOUSING
2 - REFLECTOR
3 - CONNECTOR
4 - MOTOR
5 - MOUNT
VALAMPS/LIGHTING - EXTERIOR 8L - 15
FRONT TURN/PARK/SIDE MARKER LAMP BULB (Continued)

(4)Rotate the headlamp leveling motor counterclock-
wise about 30 degrees and pull it straight out from the
mount integral to the front lamp unit housing (Fig. 28).
(5) Stabilize the front lamp unit reflector with one
hand, then use the other hand to pull the headlamp
leveling motor away from the reflector until the ball
on the end of the motor pushrod unsnaps from the
bracket on the reflector.
(6) Remove the headlamp leveling motor from the
mount on the front lamp unit housing.
INSTALLATION
(1) Position the headlamp leveling motor to the
mount on the front lamp unit housing (Fig. 28).
(2) Snap the ball on the end of the headlamp lev-
eling motor into the bracket on the front lamp unit
reflector.
(3) Push the headlamp leveling motor into the
mount integral to the front lamp unit housing until it
is fully seated, then rotate the motor clockwise about
30 degrees to lock it into place (Fig. 27).
(4) Reconnect the front lamp unit wire harness
connector to the connector receptacle for the head-
lamp leveling motor.
(5) Position the front lamp unit rear cover onto the
lamp housing and engage the retainers over each
side of the cover to secure it (Fig. 26).
(6) Reconnect the battery negative cable.
HEADLAMP LEVELING SWITCH
REMOVAL
(1)Disconnect and isolate the battery negative cable.
(2) Remove the cluster bezel from the instrument
panel (Fig. 29). (Refer to 23 - BODY/INSTRUMENT
PANEL/CLUSTER BEZEL - REMOVAL).
(3) From the back of the cluster bezel, squeeze the
two latches on the headlamp leveling switch body
and push the switch out through the face of the bezel
(Fig. 30).
(4) Remove the headlamp leveling switch from the
face of the cluster bezel.
Fig. 28 Headlamp Leveling Motor Remove/Install
1 - PUSHROD
2 - MOTOR
3 - MOUNT
4 - BRACKET
5 - REFLECTORFig. 29 Headlamp Leveling Switch
1 - HEADLAMP LEVELING SWITCH
2 - SCREW (2)
3 - CLUSTER BEZEL
4 - TO REAR WINDOW DEFOGGER SWITCH (OPTIONAL)
5 - TO HEADLAMP LEVELING SWITCH
6 - TO FOG LAMP SWITCH (OPTIONAL)
Fig. 30 Headlamp Leveling Switch Remove/Install
1 - FOG LAMP SWITCH
2 - LATCH (2)
3 - CLUSTER BEZEL
8L - 16 LAMPS/LIGHTING - EXTERIORVA
HEADLAMP LEVELING MOTOR (Continued)

INSTALLATION
(1) Position the headlamp leveling switch to the
proper mounting hole on the face of the cluster bezel
(Fig. 29).
(2) Using hand pressure, push the headlamp level-
ing switch firmly and evenly into the switch mount-
ing hole of the cluster bezel until both of the latches
on the switch body are fully engaged.
(3) Reinstall the cluster bezel onto the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
CLUSTER BEZEL - INSTALLATION).
(4) Reconnect the battery negative cable.
HIGH BEAM HEADLAMP BULB
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Disengage and swing the retainers that secure
the front lamp unit rear cover to each side of the
lamp housing and remove the cover (Fig. 31).
(3) Disconnect the front lamp unit wire harness
connector from the high beam headlamp bulb base
(Fig. 32).
(4) Disengage the high beam headlamp bulb
retainer by pushing it slightly toward the front lamp
unit housing and outward from the bulb base, then
pivot the retainer off of the bulb base.
(5) Remove the high beam headlamp bulb from the
integral bulb holder on the front lamp unit reflector.
INSTALLATION
(1) Position the high beam headlamp bulb into the
integral bulb holder on the front lamp unit reflector.
Be certain that the lugs on the bulb base are
engaged in the recesses of the bulb holder (Fig. 31).
(2) Engage the high beam headlamp bulb retainer
by pivoting it over the bulb base, pressing it slightly
outward from the bulb base and toward the front
lamp unit housing, then inward toward the side of
the bulb base.
(3) Reconnect the front lamp unit wire harness
connector to the high beam headlamp bulb base.
(4) Position the front lamp unit rear cover onto the
lamp housing and engage the retainers over each
side of the cover to secure it (Fig. 13).
(5) Reconnect the battery negative cable.
LICENSE PLATE LAMP BULB
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the license plate lamp unit from its
mounting location, but do not disconnect it from the
vehicle wire harness. (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/LICENSE PLATE
LAMP UNIT - REMOVAL).
(3) Grasp the lamp housing firmly in one hand,
then disengage the bulb from between the bulb hold-
ers with the other hand (Fig. 33).
Fig. 31 Front Lamp Unit Bulbs Remove/Install
1 - COVER RETAINER (2)
2 - BULB RETAINER (3)
3 - FOG LAMP BULB (OPTIONAL)
4 - COVER
5 - LOW BEAM BULB
6 - POSITION BULB
7 - HIGH BEAM BULB
8 - TURN/PARK/SIDE MARKER BULB
9 - FRONT LAMP UNIT
Fig. 32 High Beam Headlamp Bulb Remove/Install
1 - LAMP HOUSING
2 - BULB RETAINER
3 - CONNECTOR
4 - BULB BASE
VALAMPS/LIGHTING - EXTERIOR 8L - 17
HEADLAMP LEVELING SWITCH (Continued)

INSTALLATION
(1) Grasp the license plate lamp housing firmly in
one hand, then engage the bulb between the bulb
holders with the other hand (Fig. 33).
(2) Reinstall the license plate lamp unit to its
mounting location. (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/LICENSE PLATE
LAMP UNIT - INSTALLATION).
(3) Reconnect the battery negative cable.
LICENSE PLATE LAMP UNIT
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Using hand pressure, press the right side of
the license plate lamp housing toward the left
against the spring pressure of the retaining clip, then
pull the right side of the lamp downward to disen-
gage it from the mounting hole (Fig. 34).
(3) Pull the license plate lamp housing slightly to
the right to disengage the left side of the unit from
the mounting hole.
(4) Disconnect the one or two vehicle wire harness
connections from the terminals on the back of the
license plate lamp unit.(5) Remove the license plate lamp unit from the
vehicle.
INSTALLATION
(1) Position the license plate lamp unit to the
mounting hole on the vehicle (Fig. 34).
(2) Reconnect the one or two vehicle wire harness
connections to the terminals on the back of the
license plate lamp unit.
(3) Engage the left side of the license plate lamp
unit into the left side of the mounting hole.
(4) Using hand pressure, press the right side of
the license plate lamp housing toward the left
against the spring pressure of the retaining clip, then
push the right side of the lamp upward to engage it
into the right side of the mounting hole.
(5) Reconnect the battery negative cable.
LOW BEAM HEADLAMP BULB
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Disengage and swing the retainers that secure
the front lamp unit rear cover to each side of the
lamp housing and remove the cover (Fig. 35).
Fig. 33 License Plate Lamp Bulb Remove/Install
1 - LAMP HOUSING
2 - WIRE HARNESS CONNECTOR (1 or 2)
3 - BULB
Fig. 34 License Plate Lamp Unit Remove/Install
1 - LAMP HOUSING
2 - LENS
Fig. 35 Front Lamp Unit Bulbs Remove/Install
1 - COVER RETAINER (2)
2 - BULB RETAINER (3)
3 - FOG LAMP BULB (OPTIONAL)
4 - COVER
5 - LOW BEAM BULB
6 - POSITION BULB
7 - HIGH BEAM BULB
8 - TURN/PARK/SIDE MARKER BULB
9 - FRONT LAMP UNIT
8L - 18 LAMPS/LIGHTING - EXTERIORVA
LICENSE PLATE LAMP BULB (Continued)